Builder: Larry Erd, Pompano Beach, Fla. Plans: 'Black Widow' Cost: $689.15 1.) Plans and Parts (PDF,.3MB, requires ) Erd and his 7-year-old son, Harrison, used $14.99 plans for the 'Black Widow' go-kart from. Plans like these, whether they are free or require a fee, often give frame dimensions but leave steering, axle, throttle and cable connections up to the builder. Browse parts suppliers' websites to find additional advice on materials and methods.
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'You're on your own, but that's the fun of it,' Erd says. 2.) Frame Use a hacksaw or chop saw to cut metal stock to length. Clamp the steel in a vise and file or grind the cut edges smooth. Using a MIG welder, tack together the parts to check for a good fit, and make final welds to complete the frame. 3.) Steering Weld an upper steering block to the top of the kart's steering post. Weld the lower steering block to the front of the frame. Screw the steering wheel to the steering shaft and thread the shaft assembly through the upper and lower blocks.
Bolt a pair of spherical rod ends to the steering arm at the bottom of the shaft, using nylock nuts. Weld spindle brackets to the front corners of the frame. Bolt the tie rods' opposite ends to the brackets' arms and connect the rods to both ends. Thread each bracket's stub axle into the front wheels' hubs. Mount the front tires on rims and bolt the rims to the hubs.
Erd adjusted the positions of the steering shaft and tie rods until the steering performed properly. Selfmade Records Chronik 2. 4.) Rear Axle Weld bearing hangers to the bottom face of the frame's 10-inch rear legs.
Center the sprocket, Uni-Hub and brake drum on the axle. Wedge bearings between a pair of bearing cassettes and use the hardware in a bearing kit to fasten the cassettes to both hangers. (Expect to adjust the axle parts again.) On the axle ends, mount wheel hubs, fit rear tires onto the rims and bolt the rims to the wheel hubs. 5.) Engine Buy accessories together with the engine to ensure compatibility. Weld a mounting plate to the rear center of the frame, and bolt the engine to it.
Add a clutch to the engine crankshaft using set screws in the clutch hub. Slide the Uni-Hub along the axle to align the axle sprocket with the clutch sprocket. Weld a bent 3/8-inch rod to the frame so it crosses in front of the brake drum to anchor the brake band. Tighten the set screws on the Uni-Hub, drum and bearings. Loop chain around both sprockets. Remove links to adjust the chain so it has ½ inch of play. 6.) Cables Attach brake and throttle cables to the left and right foot pedals.